Method for fabricating a contact cleaning roller or belt

Abstract

A contact cleaning roller or belt fabricated by attaching a polymer-coated flexible substrate cut from flexible sheet stock to the surface of a structural core or a structural belt of a desired length. For either a CCR or CCB, an adhesive and/or resilient layer may be inserted between the flexible substrate and the structural element. The flexible substrate may be formed of metal, for example, aluminum, or plastic, for example, polyethylene terephthalate and may comprise, for example, a toothed belt having a smooth outer surface. The flexible substrate is provided with a polymeric layer having low durometer and triboelectric properties, such as novolak resin, cross-linked epoxides, polyisoprene rubber, silicone rubber, polyurethane, and norbornene-co-styrene-co-maleic anhydride. An advantage of a CCR or CCB in accordance with the invention is that the substrate and polymeric layer are easily replaced to provide a refurbished CCR or CCB.

1 . A contact cleaning device, comprising:
 a) a structural substrate having an outer surface; and   b) a flexible cleaning element formed from a flexible sheet stock and conformal to said outer surface and having self-abutting ends, wherein said flexible cleaning element includes an outer layer formed of a polymer defining a cleaning surface for said contact cleaning device.   
   
   
       2 . A contact cleaning device in accordance with  claim 1  wherein said flexible cleaning element further includes a flexible substrate selected from the group consisting of a metal sheet and a plastic sheet. 
   
   
       3 . A contact cleaning device in accordance with  claim 1  wherein said polymer is selected from the group consisting of novolak resin, cross-linked epoxides, polyisoprene rubber, silicone rubber, polyurethane, and norbornene-co-styrene-co-maleic anhydride. 
   
   
       4 . A contact cleaning device in accordance with  claim 1  wherein said structural substrate is a cylindrical core and said contact cleaning device is a contact cleaning roller. 
   
   
       5 . A contact cleaning device in accordance with  claim 1  wherein said structural substrate is an endless belt and said contact cleaning device is a contact cleaning belt. 
   
   
       6 . A contact cleaning device in accordance with  claim 1  further comprising a resilient layer between said structural substrate and said flexible cleaning element 
   
   
       7 . A method for forming a contact cleaning device, comprising the steps of:
 a) forming a structural substrate having an outer surface;   b) forming a flexible cleaning element from a flexible sheet stock having an outer layer formed of a polymer;   c) conforming said flexible cleaning element to said outer surface such that said flexible cleaning element overlaps itself over a portion thereof;   d) cutting through both layers of said flexible cleaning element in said overlapping portion to form an attachable portion and at least one waste portion;   e) removing said waste portion; and   f) attaching said attachable portion to said outer surface such that cut ends thereof from said cutting step are self-abutted to form a joint therebetween.   
   
   
       8 . A method in accordance with  claim 7  comprising the further step of applying a liquid material to fill said joint. 
   
   
       9 . A method in accordance with  claim 7  wherein said contact cleaning device is a contact cleaning roller, and wherein said structural substrate is a cylindrical core. 
   
   
       10 . A method in accordance with  claim 7  wherein said contact cleaning device is a contact cleaning belt, and wherein said structural substrate is an endless belt. 
   
   
       11 . A method for forming a contact cleaning device, comprising the steps of:
 a) forming a structural substrate having an outer surface;   b) forming a flexible cleaning element from a flexible sheet stock having an outer layer formed of a polymer;   c) cutting said flexible cleaning element to a length substantially equal to the circumference of said structural substrate;   d) joining together the ends of said cut length of flexible cleaning element to form a tubular element having a diameter substantially equal to the circumference of said structural substrate; and   e) sliding said tubular element axially over said structural substrate to a predetermined axial position thereupon.   
   
   
       12 . A method in accordance with  claim 11  comprising the further step of securing said tubular element to said mandrel. 
   
   
       13 . A method in accordance with  claim 11  wherein said contact cleaning device is a contact cleaning roller, and wherein said structural substrate is a cylindrical core. 
   
   
       14 . A method in accordance with  claim 11  wherein said contact cleaning device is a contact cleaning belt, and wherein said structural substrate is an endless belt.